Progress in modeling of electrical discharge machining process

Electrical discharge machining (EDM) is a machining method for cutting hard metals to produce complex shapes and deep holes through arc erosion, and has become a popular machining method. Modelling the EDM process requires multiple model types to simulate the process. This study systematically reviews the progress of EDM process modelling. First, existing EDM finite element method (FEM) models including single-spark simulations, multi-spark simulations, hybrid machining simulations, and machining for non-conductive advanced ceramics are analyzed from the modeling to the simulation application. Second, the material removal mechanism, machining process simulation, and machining performance are reviewed in the application of the molecular dynamics (MD) models. Third, simulation applications including discharge channel characteristics, debris and bubble movement, and liquid-phase electrodes in the flow field models are compared and analysed. The FEM, MD and flow field models are compared in terms of similarity, individuality and complementarity, and the relevant research areas that may attract attention in the future are put forward.